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Honeycomb structure and method of producing the same

a honeycomb and structure technology, applied in the field of honeycomb structure, can solve the problems of difficult to handle the honeycomb main body, difficult to separate the coating layer, and breakage of the exposed partition wall, so as to achieve the effect of preventing the separation of the coating layer and producing the same easily and inexpensively

Inactive Publication Date: 2011-07-19
NGK INSULATORS LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0010]A known honeycomb structure including such a coating layer has a problem in which the coating layer is separated when thermal shock or vibration is encountered since the coating layer exhibits low adhesion to the outer wall forming the cell structure. The patent document 2 discloses a production method in which the outer circumference of a ceramic honeycomb main body integrally extruded without forming an outer wall is coated to form a shell layer. According to this production method, since the partition wall is exposed on the outer circumferential surface, the exposed partition wall may break when handling the ceramic honeycomb main body. This makes it difficult to handle the ceramic honeycomb main body. The outer circumferential portion of the honeycomb structure has been reinforced by suppressing a cell twist utilizing a recent extrusion technology and die technology and improving the reinforcement design such as reinforcing the outer circumferential portion using a rib. However, the accuracy of the external diametrical shape of the honeycomb structure must be further improved since deformation occurs during drying or firing after forming.
[0011]The present invention has been achieved in view of the problems of the related-art technologies. An object of the present invention is to provide a honeycomb structure in which a coating layer is firmly secured to an outer wall forming a cell structure so that separation of the coating layer is effectively prevented, and a method of producing the same.
[0021][9] The method of producing a honeycomb structure according to [7], wherein the cut portion is formed by at least partially removing the outer wall forming the cell structure by reducing the amount of the forming clay supplied to part of a portion forming the outer wall (outer wall forming portion) or blocking flow of the forming clay in a forming die used during forming.
[0022]In the honeycomb structure according to the present invention, the coating layer is firmly secured to the outer wall forming the cell structure so that separation of the coating layer is effectively prevented. The method of producing a honeycomb structure according to the present invention allows such a honeycomb structure to be easily and inexpensively produced.

Problems solved by technology

A known honeycomb structure including such a coating layer has a problem in which the coating layer is separated when thermal shock or vibration is encountered since the coating layer exhibits low adhesion to the outer wall forming the cell structure.
According to this production method, since the partition wall is exposed on the outer circumferential surface, the exposed partition wall may break when handling the ceramic honeycomb main body.
This makes it difficult to handle the ceramic honeycomb main body.

Method used

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  • Honeycomb structure and method of producing the same
  • Honeycomb structure and method of producing the same

Examples

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example 1

[0073]A cordierite raw material containing talc, kaolin, and alumina as the main raw ingredients was mixed with water, a binder, a surfactant, and the like. The components were dispersed / mixed and kneaded to obtain a forming raw material. The forming raw material was extruded in the shape of a column using a kneading machine, and then extruded using an extruder to obtain a tubular cell (honeycomb) formed product having a partition wall partitioning a plurality of cells serving as fluid channels and an outer wall integrally formed with the partition wall. A honeycomb structure was produced using the resulting formed product. Specifically, the resulting formed product was dried and cut to a specific length to obtain a dried product. After alternately plugging the cells on each end face of the dried product, the resulting product was fired to obtain a fired product. In this example, the outer wall was provided with cut portions by reducing the amount of forming clay for the outer wall ...

example 2

[0100]A honeycomb structure configured in the same manner as the honeycomb structure according to Example 1 was obtained, and the outer circumferential surface (outer circumferential surface of the coating layer) of the honeycomb structure was ground to obtain a honeycomb structure according to Example 2. The resulting honeycomb structure was subjected to measurements and evaluations of various property values in the same manner as in Example 1. The measurement and evaluation results are shown in Table 1. The honeycomb structure according to Example 2 exhibited particularly excellent external diametrical shape accuracy.

examples 3 to 7

[0103]Honeycomb structures (Examples 3 to 7) were produced in the same manner as in Example 1 except for forming cell structures provided with cut portions of different shapes by changing the percentage of reducing the amount of forming clay for the outer wall forming portion when extruding the cell structure. The shape of the cut portions on the surface of the cell structure obtained by extrusion was determined. FIG. 7 is a photograph of the surface of the cell structure obtained in Example 3, FIG. 8 is a photograph of the surface of the cell structure obtained in Example 4, FIG. 9 is a photograph of the surface of the cell structure obtained in Example 5, FIG. 10 is a photograph of the surface of the cell structure obtained in Example 6, and FIG. 11 is a photograph of the surface of the cell structure obtained in Example 7. The resulting honeycomb structures were subjected to measurements and evaluations of various property values in the same manner as in Example 1. These honeycom...

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Abstract

The present invention provides a honeycomb structure in which a coating layer is firmly secured to an outer wall forming a cell structure so that separation of the coating layer is effectively prevented. A honeycomb structure according to the present invention includes a cell structure having a porous partition wall partitioning a plurality of cells serving as fluid channels and an outer wall integrally formed with the partition wall, and a coating layer disposed on the surface of the outer wall forming the cell structure, a depression / protrusion portion and / or a cut portion formed by partially removing the surface of the outer wall being formed on the surface of the outer wall, and the coating layer being disposed to cover the surface of the outer wall.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]The present invention relates to a honeycomb structure and a method of producing the same. More particularly, the present invention relates to a honeycomb structure including a coating layer disposed to cover an outer wall forming a cell structure, and a method of producing the same.[0003]2. Description of Related Art[0004]A ceramic honeycomb structure has been used as a filter for trapping particulate (particularly diesel particulate) contained in automotive exhaust gas (diesel particulate filter: DPF), or a catalyst carrier for supporting a catalyst for purifying nitrogen oxide (NOx), carbon monoxide (CO), hydrocarbons (HC), and the like contained in exhaust gas.[0005]The above honeycomb structure includes a cell structure having a porous partition wall partitioning a plurality of cells serving as fluid channels and an outer wall formed on the outer circumference of the partition wall. The honeycomb structure is produ...

Claims

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Application Information

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Patent Type & Authority Patents(United States)
IPC IPC(8): B32B3/12
CPCB01D39/2093B01J35/04B28B3/2672B28B11/12B28B19/0038C04B35/195C04B38/0009C04B41/009C04B41/5024C04B41/5025C04B41/85C04B38/0074C04B38/0645C04B41/50C04B41/4539C04B41/53C04B38/0006Y10T428/24149C04B2111/00129C04B2111/00793C04B2111/0081F01N3/0222F01N3/2828F01N2330/30F01N2510/00B01D2239/0478Y10T428/24157
Inventor ICHIKAWA, YUKIHITO
Owner NGK INSULATORS LTD